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Abstract:

A cutting apparatus for cutting a corner from sheet material to a
selectable profile. In one set of embodiments, the cutting apparatus
comprises a cutting assembly that includes a cutting element having a
plurality of cutting profiles wherein each cutting profile may have a
unique profile. The cutting assembly is configured such that an active
cutting profile is selectable from the plurality of cutting profiles
available on the cutting element. Engagement of the active cutting
profile with one or more pieces of sheet material cuts a corner from the
sheet material to a profile indicative of the active cutting profile.
Cutting profiles may include curves having a uniform or variable radius
of curvature and other forms appropriate for cutting a corner of sheet
material.

Claims:

1. An apparatus for cutting a portion from sheet material, comprising:a
first member operatively coupled to a second member; anda cutting
assembly operatively coupled to the first member, the cutting assembly
including a plurality of cutting profiles,wherein an active cutting
profile is selectable from among the plurality of cutting profiles and is
engageable with one or more pieces of sheet material.

2. The apparatus of claim 1, wherein each of the plurality of cutting
profiles has a unique cutting profile.

3. The apparatus of claim 2, wherein the first cutting profile is
substantially circular and has a first radius of curvature, and wherein
the second cutting profile is substantially circular and has a second
radius of curvature.

4. The apparatus of claim 2, wherein the plurality of cutting profiles
includes a first cutting profile and a second cutting profile disposed
about 180 degrees from the first cutting profile.

5. The apparatus of claim 1, wherein the cutting assembly is rotatably
coupled to the first member, and wherein the active cutting profile is
selectable by rotation of the cutting assembly.

6. The apparatus of claim 1, further including a selection member
operatively coupled to the cutting assembly and orientable between an
unsecured orientation and a secured orientation,wherein the active
cutting profile is selectable from among the plurality of cutting
profiles when the selection member is in the unsecured configuration,
andwherein the active cutting profile is substantially fixed with respect
to the first member where the selection member is in the secured
configuration.

7. The apparatus of claim 6, wherein the selection member is at least
partially received in the first member when the selection member is in
the secured orientation, and wherein the selection member is at least
partially elevated away from the first member when the selection member
is in the unsecured orientation.

8. The apparatus of claim 1, wherein the cutting element is removable from
the apparatus and is interchangeable with a new cutting element.

9. An apparatus for cutting a portion from sheet material, comprising:a
first member operatively coupled to a second member; anda cutting
assembly operatively coupled to the first member, the cutting assembly
comprising:a housing including an upper surface and a lower surface;a
cutting element slidingly constrained between the upper surface and the
lower surface, the cutting element including a plurality of cutting
profiles;at least one biasing member disposed between the cutting element
and the upper surface, the at least one biasing member biasing the first
member away from the second member; anda selection member operatively
coupled to the cutting assembly,wherein an active cutting profile is
selectable from among the plurality of cutting profiles by operation of
the selection member, andwherein the active cutting profile is engageable
with one or more pieces of sheet material.

10. The apparatus of claim 9, wherein each of the plurality of cutting
profiles has a unique cutting profile.

11. The apparatus of claim 10, wherein the plurality of cutting profiles
includes a first cutting profile and a second cutting profile disposed
about 180 degrees from the first cutting profile.

12. The apparatus of claim 11, wherein the cutting profile is
substantially circular and has a first radius of curvature and the second
cutting profile is substantially circular and has a second radius of
curvature.

13. The apparatus of claim 12, wherein the cutting assembly is rotatably
coupled to the first member, and wherein the active cutting profile is
selectable by rotation of the selection member.

14. The apparatus of claim 9 wherein the selection member is orientable
between an unsecured orientation and a secured orientation,wherein the
active cutting profile is selectable from among the plurality of cutting
profiles when the selection member is in the unsecured orientation,
andwherein the active cutting profile is substantially fixed with respect
to the first member when the selection member is in the secured
orientation.

15. The apparatus of claim 14, wherein the selection member is at least
partially received in the first member when the selection member is in
the secured orientation, and wherein the selection member is at least
partially elevated away from the first member when the selection member
is in the unsecured orientation.

16. The apparatus of claim 9, wherein the cutting assembly is removable
and interchangeable with a new cutting assembly.

17. An apparatus for cutting a portion from sheet material, comprising:a
first member operatively coupled to a second member;a cutting assembly
rotatably coupled to the first member; anda selection member rotatably
coupled to the cutting assembly, the selection member orientable between
an unsecured orientation and a secured orientation,wherein an active
cutting profile is selectable from among the plurality of cutting
profiles by rotation of the selection member when the selection member is
in the unsecured orientation,wherein the active cutting profile is
substantially fixed with respect to the first member when the selection
member is in the secured orientation, andwherein the active cutting
profile is engageable with one or more pieces of sheet material.

18. The apparatus of claim 17, wherein the selection member is at least
partially received in the first member when the selection member is in
the secured orientation, and wherein the selection member is at least
partially elevated away from the first member when the selection member
is in the unsecured orientation.

19. The apparatus of claim 17, wherein the cutting assembly is rotatable
about an axis substantially normal to a plane defined by one or more
pieces of sheet material engageable by the active cutting profile.

20. The apparatus of claim 19, wherein the plurality of cutting profiles
includes a first cutting profile and a second cutting profile disposed
about 180 degrees from the first cutting profile.

Description:

FIELD OF THE INVENTION

[0001]The present invention relates generally to the field of devices to
cut sheet material. More particularly the present invention relates to
devices for cutting the corners from sheet material.

BACKGROUND OF THE INVENTION

[0002]This section is intended to provide a background or context to the
invention that is recited in the claims. The description herein may
include concepts that could be pursued, but are not necessarily ones that
have been previously conceived or pursued. Therefore, unless otherwise
indicated herein, what is described in this section is not prior art to
the description and claims in this application and is not admitted to be
prior art by inclusion in this section.

[0003]Various conventional systems for cutting a corner from sheet
material are known. Some such systems provide for a corner cutting system
comprising at least one moveable cutting element configured to cut a
corner from a sheet of material. The cutting element is generally coupled
to a handle or other member for operation of the cutting element. The
handle may be biased with respect to a base structure that is configured
to accept the sheet material and the cutting element. Some such systems
allow for the disassembly of the cutting element from the system and
installation of a different cutting element, while other systems include
multiple cutting elements and a base, with multiple corresponding cutting
areas preconfigured to accept the cutting elements.

SUMMARY OF THE INVENTION

[0004]Various embodiments of the present invention comprise systems and
methods for cutting a corner from one or more pieces of sheet material.
Embodiments of the system are configurable such that corners of sheet
material may be cut to multiple unique profiles.

[0005]In one set of embodiments, a cutting apparatus comprises a cutting
assembly that includes a cutting element having a plurality of cutting
profiles, wherein each cutting profile may have a unique profile. The
cutting assembly is operatively coupled to at least one of a pair of
operatively coupled handles. The cutting assembly is configured such that
an active cutting profile is selectable from the plurality of cutting
profiles available on a cutting element. A selection tab operatively
coupled to the cutting assembly may be provided for selection of the
active cutting profile. The selection tab may be configured such that it
can be orientated in a secured orientation, where the selection tab is at
least partially received in one of the handles, or in an unsecured
orientation, where the selection tab is at least partially elevated away
from the handle for efficient operation. In the unsecured orientation,
the active cutting profile may be selected by operation of the selection
tab. In the secured orientation, the active cutting profile is
substantially constrained for cutting operations. By compressing the
operatively coupled handles, the active cutting profile engages and cuts
a corner from the one or more pieces of sheet material to a profile
indicative of the active cutting profile. Cutting assemblies may include
a plurality of cutting profiles having unique profiles, such as curves
having a uniform or variable radius of curvature appropriate for cutting
a corner from sheet material.

[0006]Embodiments of the present invention permit a corner having a
selected profile to be cut from sheet material. A convenient flip-up
selection tab may be provided to permit selection of the active cutting
profile from a plurality of cutting profiles available on the corner
cutter. The flip-up tab also ensures that the active cutting profile is
properly aligned with the material to be cut and further secures the
active cutting profile with respect to the handles of the corner cutter
during cutting operations. By providing a plurality of cutting profiles
that are conveniently selectable, an efficient apparatus for cutting a
corner from sheet material is provided.

[0007]These and other advantages and features of the invention, together
with the organization and manner of operation thereof, will become
apparent from the following detailed description when taken in
conjunction with the accompanying drawings, wherein like elements have
like numerals throughout the several drawings described below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a top perspective view of one embodiment of the present
invention, showing a top handle, a bottom handle, a cutting assembly, and
selection tab;

[0009]FIG. 2 is a bottom perspective view of the corner cutter of FIG. 1;

[0010]FIG. 3 is an exploded view of the corner cutter of FIG. 1, showing
components of the corner cutter including a cutting element, an upper
collar, and a rotator;

[0011]FIG. 4 is a bottom perspective view with a piece of sheet material
inserted in the corner cutter of FIG. 1;

[0012]FIG. 5A is a detailed bottom perspective view of the cutting element
of FIG. 3;

[0013]FIG. 5B is a detailed top perspective view of the cutting element of
FIG. 3;

[0014]FIG. 6A is a detailed bottom perspective view of the upper collar of
FIG. 3;

[0015]FIG. 6B is a detailed top perspective view of the upper collar of
FIG. 3;

[0017]FIG. 8A is a detailed bottom perspective view of the rotator of FIG.
3; and

[0018]FIG. 8B is a detailed top perspective view of the rotator of FIG. 3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019]FIG. 1 illustrates a corner cutter 10 constructed in accordance with
an embodiment of the present invention. The corner cutter 10 comprises a
top handle 100 operatively coupled to a bottom handle 200 at a hinge 130.
The cutting system may further comprise a cutting assembly 400
operatively coupled to the top handle 100. The cutter assembly may
further be selectively orientated with respect to the top handle 100 by
operation of a selection tab 140.

[0020]In the embodiment of FIG. 1, the top handle 100 generally comprises
an elongated member including a top member 110 and an upper side member
120 extending downward from the top member 110. The upper side member is
disposed about at least a portion of the perimeter of the top member 110.
As seen in FIG. 3, the upper side member 120 includes a pair of coaxial
holes 330 disposed at the location of the hinge 130. The bottom handle
200 has a substantially similar configuration to that of the of the top
handle 100 and generally comprises an elongated member including a bottom
member 210 and a lower side member 220 extending upward from the bottom
member 210. The lower side member is disposed about at least a portion of
the perimeter of the bottom member 210. The lower side member 200
includes a pair of coaxial axle portions 230 disposed at the location of
the hinge 130. The pair of coaxial holes 330 of the upper handle are
configured to operatively align with the corresponding pair of axle
portions 230 to rotatably couple the top handle 100 and the bottom handle
200. Application of a compressive load on the top handle 100 and the
bottom handle 200 decreases the distance between a leading edge 170 of
the top handle 100 and a leading edge 270 of the bottom handle 200.

[0021]As seen in FIG. 3, a bottom surface 310 disposed on the underside of
the top member 110 and a medial surface 320 disposed on the interior of
the upper side member 120 partially form a region 340 on the underside of
the top handle 100. The cutting assembly 400 is partially contained
within the region 340. The cutting assembly 400 is coupled to the top
handle, with a bracket 360 and one or more fasteners 355. Alternatively,
the cutting assembly 400 can be coupled to the top handle 100 by other
methods of securement known in the art. One or more fasteners 355 may
further secure a material guide 350 to the cutting assembly 400 and the
top handle 100. The material guide 350 is disposed partially within the
region 340 and comprises a raised surface 356, a guide slot 352, and a
first material stop 358. As seen in FIG. 2, the guide slot 352 is
configured to accept one or more sheets of material to be cut in the
corner cutter 10. A piece of material 50 is slid under the raised surface
356 up to the first material stop 358. As seen in FIG. 4, the material 50
is further orientated by positioning the material such that it abuts a
second material stop 124 disposed on the upper side member 120.
Optionally, positioning indicia 354 may be included on the material guide
350 to guide orientation of the material with respect to the corner
cutter 10.

[0022]FIG. 3 illustrates an embodiment of the corner cutter 10 with the
components of the cutting assembly 400. The cutting assembly 400
comprises a lower collar 410, a cutting die 420, one or more biasing
members 430, an upper collar 440, and a rotator 480. The cutting die 420
is slidingly constrained within a housing formed by the lower collar 410
and the upper collar 440. The lower collar 410 is secured to the upper
collar 440 by one or more fasteners 405 passing through one or more
corresponding holes 412 disposed in the lower collar 410 and threadedly
engaging one or more corresponding bosses 442 disposed on the upper
collar 440. The one or more biasing members 430 are positioned between
and are operatively coupled to the upper collar 440 and the cutting die
420 such that the one or more biasing members 430 assert a substantially
normal biasing force on the cutting die 420, biasing the cutting die 420
toward the lower collar 410. The upper collar 440 and the cutting die 420
may further include one or more biasing member retaining protrusions 428
configured to operatively couple to and assist in maintaining the
orientation of the corresponding one or more biasing members 430. The
height of the biasing member retaining protrusions 428 may be configured
to limit translation of the cutting die 420 between the lower collar 410
and the upper collar 440 to prevent over compression of the biasing
members 430.

[0023]In the embodiment illustrated in FIGS. 5A and 5B, the cutting die
420 comprises a bottom surface 510 and a top surface 520. A cutting
element 530 is disposed on the top surface 520 and extends upwardly from
the top surface 520 and is configured with one or more cutting profiles.
In the embodiment of FIG. 5A, a first cutting profile 532 and a second
cutting profile 534 are orientated on the cutting element 530 about 180
degrees from each other. However, other configurations of the cutting die
420 and the cutting element 530 may be constructed. For example, an
embodiment of the cutting element 530 could be constructed with four
cutting profiles, each cutting profile located about 90 degrees from an
adjacent cutting profile. Also, the cutting die 420 could be constructed
with more than one cutting element 530, each including one or more
cutting profiles. Each cutting profile may have a unique profile. In the
embodiment of FIG. 5A, the first cutting profile 532 is configured with a
profile having a particular radius of curvature, and the second cutting
profile 534 is configured with a profile having a lesser radius of
curvature than that of the first cutting profile 532. Numerous
configurations of the cutting profiles may be constructed having greater
or lesser radii of curvature than illustrated or having alternative
profiles, including, but not limited to, linear, elliptical, parabolic,
corrugated, or other profiles desirable for cutting a corner from sheet
material. The cutting patterns may also comprise more irregular shapes,
resulting in a wide variety of potential patterns.

[0024]As shown in FIG. 3, the lower collar 410 includes a through hole 416
that provides access to the bottom surface 510 of the cutting die 420. As
seen in FIG. 7, the bottom handle 200 includes an actuating probe 250
extending upwardly from an inner surface 212 of the bottom member 210 of
the bottom handle 200. The actuating probe 250 engages the bottom surface
510 of the cutting die 420 when a compressive load is applied to the top
handle 100 and the bottom handle 200. Further compression of the top
handle 100 and the bottom handle 200 results in application of a
substantially normal force to the bottom surface 510. Upon sufficient
compressive load to the top handle 100 and the bottom handle 200, the
biasing force of the biasing members 430 is overcome, compressing the
biasing members 430 and translating the cutting die 420 toward the upper
collar 440. Reduction of the compressive load from the top handle 100 and
the bottom handle 200 results in the one or more biasing members 430
acting with the biasing force on the cutting die 420 to translate the
cutting die 420 and the actuating probe 250 back toward to their
respective initial positions. The one or more biasing members 430 are
selected to provide sufficient biasing force to actuate the return of the
cutting die 420 to its initial position and to return the top handle 100
and the bottom handle 200 to an open orientation with release of the
compressive load. The one or more biasing members 430 are also selected
to provide for comfortable operation so that a reasonable load applied by
a user to the top handle 100 and the bottom handle 200 actuates the
cutting die 420 to cut the corner from the sheet material 50. Coil
springs may be used as the biasing members 430 in a particular
embodiment. In other embodiments, alternative biasing structures known in
the art may be used as the biasing members.

[0025]FIGS. 6A and 6B show an embodiment of the upper collar 440 in
detail. The upper collar 440 includes a opening 441 that permits passage
of the cutting element 530 during operation. As shown, the opening 441
has a substantially similar shape to that of the cutting element 530 but
is slightly larger to permit sufficient clearance for the passage of the
cutting element 530. Correlation of the shape and size of the opening 441
to the cutting element 530 enhances the cutting efficacy of the corner
cutter 10. The upper collar 440 also includes one or more material slots
444 disposed around the perimeter of the upper collar 440 and configured
for sliding the material 50 into the upper collar 440 for cutting. The
location of the one or more material slots 444 correspond to the
configuration of the cutting element 530. For example, for the embodiment
of the cutting element depicted in FIG. 5A, the one or more material
slots 444 are configured for access by the material 50 to the first
cutting profile 532 and to the second cutting profile 534.

[0026]FIG. 3 shows an assembly comprising the lower collar 410, the
cutting die 420, and the upper collar 440, which is coupled to the
rotator 480, and thereby forming the cutting assembly 400. The rotator
480 is operatively coupled to the top handle 100 and retained by the
bracket 360. The bracket 360 is secured to the top handle 100 with the
fasteners 355 or by other methods of securement known in the art. The
bracket 360 permits rotation of the rotator 480 within the top handle 100
and the cutting assembly 400 about an axis substantially normal to a
plane defined by the material 50 inserted into the corner cutter 10, as
shown in FIG. 4. The cutting assembly 400 is rotated with respect to the
top handle 100 to align the cutting element 530 such that a cutting
profile of the cutting element 530, such as the first cutting profile 532
or the second cutting profile 534, is substantially aligned in relation
to the first material stop 358 and the second material stop 124 and a
corner of the material 50.

[0027]The cutting assembly 400 may also be configured such that it is
disengageable from the top handle 100 and interchanged with a new cutting
assembly 400. Interchange of the cutting assembly permits replacement of
the cutting element 530 if it is worn or insertion of a cutting assembly
400 with different cutting profiles. Alternatively, the cutting assembly
400 may also be configured such that the cutting element 530 is
interchangeable instead of the whole of the cutting assembly 400.
Interchange of the cutting element 530 offers the same advantages of
interchange of the cutting assembly 400 in a potentially more economical
manner.

[0028]As depicted in FIG. 5A, the cutting die 420 includes the cutting
element 530 having a first cutting profile 532 and a second cutting
profile 534, the cutting assembly 400 is configured to be orientated with
respect to the top handle 100 in a first orientation corresponding to use
of the first cutting profile 532 and a second orientation corresponding
to use of the second cutting profile 534. The cutting profile orientated
for use is the active cutting profile. In this embodiment, the first
orientation is disposed about 180 degrees from the second orientation.
The cutting assembly 400 is capable of a full 360 degree rotation or is
alternatively limited to a rotation of about 180 degrees, with respect to
the top handle 100 to achieve the first and second orientations. A
selection tab 140 may be operatively coupled to the cutting assembly 400
to facilitate rotation of the cutting assembly 400.

[0029]As shown in FIG. 3, the selection tab 140 is operatively coupled to
the rotator 480 by an axle 148 partially residing within a through hole
145 in the selection tab 140. As seen in FIGS. 8A and 8B, a pair of
coaxial holes 488 are provided in the rotator 480 and are configured to
slidingly accept the axle 148. In this configuration, the selection tab
140 is deployed by rotating the selection tab 140 outwardly from a
lowered secured position away from the top handle 100 about the axle 148.
The selection tab 140 is readily graspable by a user in the deployed
unsecured position to assist in the rotation of the cutting assembly 400.
As illustrated in FIG. 1, the top member 110 may be configured with a tab
recess 112 to at least partial accommodate the selection tab 140 in the
top handle 100 when the selection tab 140 is in the secured position.
When rotating the cutting assembly 400, proper orientation of the of the
cutting assembly 400 in the first or the second orientation is readily
achieved by aligning the selection tab 140 with the tab recess 112. One
or more detents may also be used to secure the cutting assembly 400 in a
proper position. Additionally, by lowering the selection tab 140 into the
tab recess 112, the selection tab 140 may be substantially secured,
thereby locking the rotational position of the cutting assembly and the
active cutting profile, in the desired orientation for cutting
operations. An access recess 115 may be disposed on the top member 110
proximate to the tab recess 112 to facilitate access to the selection tab
140 when in the lowered position. Indicia representative of the cutting
profiles may be included on the selection tab 140 and/or the cutting
assembly 400 to readily indicate to the user the active cutting profile.

[0030]Material is cut with the corner cutter 10 by first selecting the
active cutting profile from the available cutting profiles of the cutting
element 530. If the cutting assembly 400 is orientated in the top handle
100 such that the desired cutting profile is not the active cutting
profile, then the cutting assembly 400 is rotated until the desired
cutting profile is positioned for use as the active cutting profile.
Rotation of the cutting assembly 400 is accomplished by lifting the
selection tab 140 from the secured position in the tab recess 112 to the
unsecured position and then rotating the selection tab 140 until the
cutting assembly 400 obtains the desired position. The rotational
position of the cutting assembly 400 is maintained by lowering the
selection tab 140 back into the tab recess 112. Next, the material 50 to
be cut is orientated in the corner cutter 10, as shown in FIG. 4.
Orientation of the material 50 is achieved by inserting a corner of the
material 50 into the material slot 444 a first edge 52 of the material 50
into the guide slot 352 and under the raised surface 356 until the first
edge 52 abuts the first material stop 358 and a second edge 54 of the
material 50 abuts the second material stop 124. Next, a compressive load
is gradually applied to the top handle 100 and the bottom handle 200
thereby reducing the distance between the leading edge 170 of the top
handle 100 and the leading edge 270 of the bottom handle 200.
Simultaneously, the actuating probe 250 engages the bottom surface 510 of
the cutting die 420 and translates the cutting die 420 toward the
material 50 captured in the upper collar 440. In translating the cutting
die 420, the active cutting profile of the cutting element 530 impinges
the material 50, thereby cutting the corner from the material 50 to the
profile of the active cutting profile. The compressive load is then
gradually removed from the top handle 100 and the bottom handle 200,
allowing the biasing force of the one or more biasing members 430 to act
on the cutting die 420 and translate the cutting die 420 back toward the
lower collar 410. Simultaneously, the distance between the leading edge
170 of the top handle 100 and the leading edge 270 of the bottom handle
200 is increased. The material 50, having been cut, is then removed from
the corner cutter 10. The process, as described immediately above, may be
repeated to cut remaining corners of the material 50 or additional
material.

[0031]Embodiments of the present invention are particularly useful for
rounding the corners of paper materials. However, one skilled in the art
will appreciate that the present invention is not limited to the rounding
of corners but may be employed to cut a variety of shapes in paper and
other relatively thin sheet materials, including fabrics, polymer and
rubber type materials, metals, and woods. Additionally, it will be
appreciated that multiple layers of the same or different materials may
be cut simultaneously using the present invention.

[0032]The foregoing description of embodiments of the present invention
have been presented for purposes of illustration and description. It is
not intended to be exhaustive or to limit the present invention to the
precise form disclosed, and modifications and variations are possible in
light of the above teachings or may be acquired from practice of the
present invention. The embodiments were chosen and described to explain
the principles of the present invention and its practical application to
enable one skilled in the art to utilize the present invention in various
embodiments and with various modifications as are suited to the
particular use contemplated.